Motor fan and guard for directing coolant air

ABSTRACT

An electric motor assembly includes a stator, a rotor, a motor housing, a rotatable shaft, a radial fan, and an air scoop. The motor housing at least partly houses the stator and rotor and presents an exterior motor surface. The rotatable shaft is associated with the rotor for rotational movement therewith, with the rotatable shaft extending along a rotational axis. The radial fan is mounted on the rotatable shaft exteriorly of the motor housing and is rotatable with the shaft to direct airflow in a radially outward direction. The air scoop extends radially outwardly relative to the radial fan and axially to receive radial airflow from the radial fan and turn the airflow axially to flow along the exterior motor surface. The air scoop includes spaced apart axially extending airflow vanes to guide the airflow as the airflow is turned axially.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is being filed contemporaneously with U.S.Nonprovisional Application Ser. No. 16/459,244, entitled HEATSINK CLAMPFOR MULTIPLE ELECTRONIC COMPONENTS, U.S. Nonprovisional Application Ser.No. 16/459,204, entitled MOTOR CONTROLLER WITH INDUCTOR MOUNTEDTRANSVERSE TO CONTROL BOARD, U.S. Design Application No. 29/696,824,entitled MOTOR CONTROLLER HOUSING, and U.S. Design Application No.29/696,823, entitled MOTOR AIR SCOOP, each of which is herebyincorporated in its entirety by reference herein.

BACKGROUND 1. Field

The present invention relates generally to electric motors. Morespecifically, embodiments of the present invention concern an electricmotor assembly including a radial fan and air scoop.

2. Discussion of Prior Art

It is common in the prior art for an electric motor assembly to includea motor housing and a motor controller mounted exteriorly to thehousing. It is well known that motor controllers develop substantialamounts of heat during motor operation. For this reason, conventionalmotor controllers include a heat sink with exterior fins to dissipateheat generated within the controller and discharge the heat to ambient.Heat sinks are generally operable to discharge heat from an enclosedcontainer, although this capability can be limited in certainapplications. For instance, exterior motor controllers often positionthe heat sink so that the fins are located adjacent the motor housing,such that heat transfer from the exterior fins is unduly limited (e.g.,such a configuration may cause air adjacent the fins to be stagnant).

In some conventional embodiments, the electric motor includes a rotatingcooling fan that provides cooling air for removing heat from an externalmotor controller. In particular, the cooling fan provides a forced flowof cooling air that is directed along the heat sink associated with themotor controller. Those of skill in the art will appreciate that theflow of cooling air across the heat sink generally enhances heattransfer from the heat sink to ambient.

However, prior art electric motors with external motor controllers areproblematic, and the associated cooling devices have severaldeficiencies. Even where the motor controller is used in combinationwith a cooling fan to force air over the heat sink, such prior artconfigurations are inefficient or fail to provide adequate heat transferfrom the motor controller. For instance, known cooling fan arrangementsproduce a cooling stream of air that is turbulent and not uniform as itreaches the heat sink.

This background discussion is intended to provide information related tothe present invention which is not necessarily prior art.

SUMMARY

The following brief summary is provided to indicate the nature of thesubject matter disclosed herein. While certain aspects of the presentinvention are described below, the summary is not intended to limit thescope of the present invention.

Embodiments of the present invention provide a fan and air scoop that donot suffer from the problems and limitations of the prior art devices,including those set forth above.

A first aspect of the present invention concerns an electric motorassembly that broadly includes a stator, a rotor, a motor housing, arotatable shaft, a radial fan, and an air scoop. The rotor is rotatablerelative to the stator. The motor housing at least partly houses thestator and rotor and presents an exterior motor surface. The rotatableshaft is associated with the rotor for rotational movement therewith,with the rotatable shaft extending along a rotational axis. The radialfan is mounted on the rotatable shaft exteriorly of the motor housingand is rotatable with the shaft to direct airflow in a radially outwarddirection. The air scoop extends radially outwardly relative to theradial fan and axially to receive radial airflow from the radial fan andturn the airflow axially to flow along the exterior motor surface. Theair scoop includes spaced apart axially extending airflow vanes to guidethe airflow as the airflow is turned axially.

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the detaileddescription. This summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter. Other aspectsand advantages of the present invention will be apparent from thefollowing detailed description of the embodiments and the accompanyingdrawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Preferred embodiments of the invention are described in detail belowwith reference to the attached drawing figures, wherein:

FIG. 1 is a perspective of an electric motor assembly constructed inaccordance with a preferred embodiment of the present invention, showingan electric motor, a motor fan assembly mounted on the electric motor,and a motor control assembly operably coupled to the electric motor;

FIG. 2 is a fragmentary perspective of the electric motor and motor fanassembly shown in FIG. 1, with the motor housing and the motor fanassembly cross-sectioned to show components inside the motor housing andthe motor fan assembly;

FIG. 3 is a fragmentary perspective of the electric motor assembly shownin FIG. 1, particularly depicting the control housing and motorcontroller of the motor control assembly, with the control housing beingcross-sectioned to depict a lower housing section, middle housingsection, upper housing section, and user interface housing of thecontrol housing;

FIG. 4 is a fragmentary perspective of the control housing and motorcontroller similar to FIG. 3, but taken from the opposite side,depicting a cover of the user interface housing opened to provide accessto a user interface, and showing the control housing cross-sectioned todepict a power factor correction circuit board, a drive interface board,a high-voltage interface, and the user interface of the motorcontroller;

FIG. 5 is a fragmentary upper perspective of the control housing andmotor controller shown in FIGS. 3 and 4, showing the upper housingsection and user interface housing removed to depict the middle housingsection, with the middle housing section including a dividing wall todefine a low-voltage chamber that receives the drive interface board anda high-voltage chamber that receives the high-voltage interface and arelay board;

FIG. 6 is a fragmentary upper perspective of the control housing andmotor controller similar to FIG. 5, but taken from the opposite side,with the dividing wall supporting a grommet to provide a feedthroughlocation, and showing a wire harness passing through the grommet toextend between the low-voltage chamber and the high-voltage chamber;

FIG. 7 is a fragmentary perspective of the electric motor assemblysimilar to FIG. 3, but taken from the opposite end of the electricmotor, showing a control board and an inductor of the power factorcorrection circuit board mounted within a lower controller chamber;

FIG. 8 is a fragmentary upper perspective of the control housing andmotor controller, but showing the middle housing section, upper housingsection, and user interface housing removed, with the lower housingsection receiving the power factor correction circuit board;

FIG. 9 is a fragmentary top view of the control housing and motorcontroller as shown in FIG. 8, particularly depicting the inductorpositioned in an open space defined partly by the control board, withthe inductor fastener assembly securing the inductor to an uprightinductor wall;

FIG. 10 is a fragmentary exploded perspective of the control housing andmotor controller shown in FIGS. 8 and 9, with the inductor fastenerassembly including an insulation pad, silicone washer, spacer, andthreaded fastener;

FIG. 11 is a fragmentary top view of the control housing and motorcontroller shown in FIGS. 8-10, showing the inductor secured to theupright inductor wall by the inductor fastener assembly;

FIG. 12 is a fragmentary cross section of the control housing and motorcontroller taken along line 12-12 of FIG. 11;

FIG. 13 is an upper perspective of the lower housing section shown inFIGS. 8-12;

FIG. 14 is an upper perspective of the lower housing section similar toFIG. 13, but taken from the opposite side;

FIG. 15 is a fragmentary perspective of the control housing and motorcontroller shown in FIG. 3, showing the power factor correction circuitboard attached to a heat sink of the control housing, withheat-generating electrical components of the control board being clampedagainst the heat sink by a clamp assembly;

FIG. 16 is a fragmentary perspective of the heat sink and motorcontroller shown in FIGS. 3 and 15, showing the clamp assembly securedto the heat sink and spaced within a perimeter of the control board;

FIG. 17 is a fragmentary perspective of the heat sink and motorcontroller similar to FIG. 16, but showing the clamp assembly and heatsink exploded from the control board;

FIG. 18 is an enlarged fragmentary perspective of the heat sink andmotor controller shown in FIGS. 3 and 15-17, showing a clamp bar andfasteners of the clamp assembly;

FIG. 19 is a fragmentary cross section of the heat sink and motorcontroller taken along line 19-19 in FIG. 18, with the clamp barincluding a clamp margin and backing flange, and showing projections ofthe clamp margin engaging respective electrical components;

FIG. 20 is a fragmentary cross section of the heat sink and motorcontroller similar to FIG. 19, but showing a first alternative set ofheat-generating electrical components secured to the heat sink by theclamp assembly, with the clamp bar flexing so that the projectionsengage the respective electrical components;

FIG. 21 is a fragmentary cross section of the heat sink and motorcontroller similar to FIG. 20, but showing a second alternative set ofheat-generating electrical components secured to the heat sink by theclamp assembly, with the clamp bar flexing in the opposite directioncompared to FIG. 20 so that the projections engage the respectiveelectrical components;

FIG. 22 is an upper perspective of the clamp bar shown in FIGS. 3 and15-21;

FIG. 23 is a lower perspective of the clamp bar shown in FIGS. 3 and15-22;

FIG. 24 is an enlarged fragmentary perspective of the heat sink andmotor controller similar to FIG. 18, but showing a first alternativeclamp assembly embodiment securing the electrical components against theheat sink;

FIG. 25 is a fragmentary cross section of the heat sink and motorcontroller shown in FIG. 24, with the alternative clamp bar including aclamp margin, backing flange, and spacers, and showing projections ofthe clamp margin engaging respective electrical components;

FIG. 26 is an upper perspective of the alternative clamp bar shown inFIGS. 24 and 25;

FIG. 27 is a lower perspective of the alternative clamp bar shown inFIGS. 24-26;

FIG. 28 is an enlarged fragmentary perspective of the heat sink andmotor controller similar to FIG. 18, but showing a second alternativeclamp assembly embodiment securing the electrical components against theheat sink;

FIG. 29 is a fragmentary cross section of the heat sink and motorcontroller shown in FIG. 28, with the alternative clamp bar including aclamp margin and backing flange, and showing projections of the clampmargin engaging respective electrical components;

FIG. 30 is an upper perspective of the alternative clamp bar shown inFIGS. 28 and 29;

FIG. 31 is a lower perspective of the alternative clamp bar shown inFIGS. 28-30;

FIG. 32 is a fragmentary perspective of the electric motor assemblyshown in FIG. 1, with the motor fan assembly including a radial fan anda fan guard, and showing the control housing and the fan guardcross-sectioned, with the radial fan rotatably received in a fan chamberdefined between the fan guard and the motor housing;

FIG. 33 is a fragmentary perspective of the electric motor assemblysimilar to FIG. 32, but taken from the opposite end of the electricmotor;

FIG. 34 is a fragmentary side elevation of the electric motor assemblyshown in FIG. 32, with the radial fan drawing air axially into the fanchamber and directing airflow radially outwardly to an air scoop of thefan guard, with the air scoop turning the airflow axially to flowthrough the heat sink and along the exterior motor surface;

FIG. 35 is a fragmentary exploded perspective of the electric motorassembly shown in FIGS. 32-34;

FIG. 36 is a perspective of the fan guard shown in FIGS. 32-35, with thefan guard including the air scoop;

FIG. 37 is a perspective of the fan guard similar to FIG. 36, but takenfrom the opposite side;

FIG. 38 is a perspective of the radial fan shown in FIGS. 32-35, withthe radial fan including a hub and wheel;

FIG. 39 is a perspective of the radial fan similar to FIG. 38, but takenfrom the opposite side;

FIG. 40 is a front elevation of the radial fan shown in FIGS. 38 and 39,showing a wheel plate and blades of the wheel, and depicting therotational direction of the radial fan;

FIG. 41 is a side elevation of the radial fan shown in FIGS. 38-40; and

FIG. 42 is a cross section of the radial fan taken along line 42-42 ofFIG. 40.

The drawing figures do not limit the present invention to the specificembodiments disclosed and described herein. While the drawings do notnecessarily provide exact dimensions or tolerances for the illustratedcomponents or structures, the drawings, not including any purelyschematic drawings, are to scale with respect to the relationshipsbetween the components of the structures illustrated therein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning to FIGS. 1-3, an electric motor assembly 50 is constructed inaccordance with a preferred embodiment of the present invention. Theelectric motor assembly 50 is particularly configured for extendedservice in humid or wet environments. The depicted electric motorassembly 50 is preferably operable with a water pump (not shown) toprovide a powered pump assembly for a recreational swimming pool. Itwill be appreciated that the electric motor assembly 50 mayalternatively be drivingly attached to another mechanism or machine,without departing from the spirit of certain aspects of the presentinvention.

The electric motor assembly 50 broadly includes an electric motor 52, amotor fan assembly 54, and a motor control assembly 56. The electricmotor assembly 50 is preferably oriented such that a rotational shaftaxis A1 extends horizontally. However, it is permissible according tosome aspects of the present invention for the motor assembly to bealternatively oriented (e.g., where the shaft axis is arrangedvertically).

Electric Motor

The electric motor 52 is configured for use in any suitable environment.The motor 52 broadly includes a housing 60, a rotor 62, and a stator 64(see FIG. 2). The rotor 62 is preferably rotatable about the rotationalshaft axis A1 (see FIG. 2). In preferred embodiments, the stator 64 atleast substantially circumscribes the rotor 62, such that the motor 52is an inner rotor motor. It is permissible according to some aspects ofthe present invention, however, for the motor to be an outer rotormotor.

The rotor 62 preferably includes a rotor core 66, a plurality of magnets68, and a shaft 70 defining the shaft axis A1 for the rotor 62. Therotor core 66 and magnets 68 are generally located within the housing60. The shaft 70 is rotatably supported relative to the motor housing 60to rotate about the shaft axis A1. More specifically, the shaft 70 isrotatably supported by opposite, axially spaced bearings 72 (see FIG.2). In the preferred embodiment, the rotor weight is generally shared bythe bearings 72.

The shaft 70 preferably includes opposite exposed portions 74 a,b thatare exposed relative to the motor housing 60 (see FIGS. 2 and 35). Theexposed portion 74 a is configured to drivingly engage the pump, and theexposed portion 74 b is configured to drivingly engage a radial fan (aswill be discussed below).

The exposed portions 74 a,b are preferably cantilevered relative to themotor housing 60 such that respective free ends of the shaft 70 arespaced from the housing 60 (see FIG. 2). However, for some aspects ofthe present invention, the shaft could have an exposed portionalternatively located along the length of the shaft (e.g., where theexposed portion is spaced between the ends of the shaft and, moreoptionally, between bearing supports such that the exposed portion isalong a non-cantilevered portion of the shaft).

The depicted shaft 70 presents an outer shaft surface 76 to receive theradial fan (see FIG. 2), such that the exposed shaft portion 47 bsupports the fan. However, according to some aspects of the presentinvention, the fan may be indirectly driven by the rotor shaft (e.g., atransmission (not shown) could be provided between the rotor shaft andfan). It is also possible for certain inventive aspects for the radialfan to be mounted to a motor shaft that is not directly connected to themechanism powered by the motor.

Preferably, the shaft 70 of the rotor 62 defines the output shaft of themotor 52, which is drivingly connected to the pump. It will beappreciated, however, that certain aspects of the present inventioncontemplate the motor output shaft not being the rotor shaft. Forexample, the motor may alternatively be provided with a transmission(e.g., a gear drive) between the rotor shaft and output shaft, with theshafts being drivingly connected but otherwise discrete and spacedapart.

The motor housing 60 preferably includes a shell 78, endshields 80,82,and fasteners 84 (see FIGS. 1-3, 32, and 35). The housing 60 alsopresents an exterior motor surface 86 (see FIGS. 32-35). The shell 78and the endshields 80 and 82 preferably present an internal motorchamber 88 that at least substantially receives the stator 64 and therotor 62 (see FIG. 2).

In a preferred embodiment, the shell 78 extends generallycircumferentially about the stator 64. It is permissible according tosome aspects of the present invention, however, for the shell to extendin such a manner as to provide one or more flat sides, in contrast tothe preferred generally cylindrical form, or to be otherwisealternatively shaped.

The endshields 80,82 preferably support respective bearings 72. Thedepicted endshields 80 and 82 are preferably secured to the shell 78 bymeans of the fasteners 84. However, it is within the ambit of certainaspects of the present invention for the housing to have an alternativeshell and/or alternative endshields. Furthermore, the shell andendshields could be alternatively secured to one another.

In the illustrated embodiment, the endshields 80 and 82 each include abearing housing 90 that presents a bearing pocket 92 receiving therespective bearing 72 (see FIG. 2). The endshields 80 and 82 alsopresent relief openings 94 (see FIG. 2). The bearing pocket 92 and therespective relief opening 94 cooperatively provide a shaft opening 96that permits the shaft 70 to extend therethrough from the motor chamber88 to outside the housing 60 (see FIG. 2).

Again, the bearings 72 preferably cooperatively rotatably support theshaft 70. However, alternative or additional bearings, supports, orshaft supports may be provided without departing from the scope of thepresent invention.

As will be explained further below, the motor fan assembly 54 isoperable to advance airflow along the exterior motor surface 86 of themotor housing 60 to cool the motor control assembly 56. The motor fanassembly 54 is mounted externally to the motor housing 60 and includes aradial fan 98 and a fan guard 100 (see FIGS. 32-35).

Although the illustrated radial fan 98 is preferably used with thedepicted motor 52, the radial fan could be used in connection with awide range of motor configurations. For example, the shaft 70 of therotor 62 preferably extends into and out of the housing 60 so that theradial fan 98 is mounted directly on the shaft 70 and is thereby drivendirectly by the rotor 62. However, in alternative embodiments, theradial fan could be powered by the rotor without being mounted on therotor shaft (as noted above). Further, as mentioned previously,according to certain aspects of the present invention, the radial fanand rotor shaft could be interconnected by a transmission (not shown).In such alternative embodiments, the transmission could provide atransmission output shaft separate from the rotor shaft, where theradial fan is mounted on the transmission output shaft.

Motor Control Assembly

Turning to FIGS. 3-14, the motor control assembly 56 is configured toprovide adjustable operation of the electric motor 52. The illustratedelectric motor 52 is operable to drive a water pump (not shown),although the electric motor 52 could be configured to power a variety ofalternative devices without departing from the scope of certain aspectsof the present invention. The motor control assembly 56 includes acontrol housing 102, a motor controller 104, and a clamp assembly 106.

Control Housing

The control housing 102 preferably provides enclosed controller chambers108 a,b,c that are water-tight and sealed from the exterior of thecontrol housing 102 (see FIGS. 4 and 7). The controller chambers 108a,b,c are preferably sealed from the exterior to prevent water, otherfluids, or other contaminants from reaching high-voltage and low-voltagecomponents in the control housing 102. The depicted control housing 102includes a heat sink 110, a lower housing section 112, middle housingsection 114, upper housing section 116, and a user interface housing 118(see FIG. 4).

Turning to FIGS. 11-14, the lower housing section 112 includes acontinuous side wall 120 a, a bottom wall 120 b, and an upstandinghousing wall 120 c. The side wall 120 a extends about the bottom wall120 b to form a continuous perimeter margin 122 of the lower housingsection 112. The bottom wall 120 b includes a raised section 124 thatpresents a central opening 126 to receive the heat sink 110. The sidewall 120 a and bottom wall 120 b cooperatively define channels 128located on opposite sides of the raised section 124.

Turning to FIGS. 4-8, the middle housing section 114 includes acontinuous side wall 130 a, a lateral wall 130 b, and an intermediatedividing wall 130 c. The side wall 130 a extends about the lateral wall130 b and the dividing wall 130 c to form upper and lower perimetermargins 132 a,b of the middle housing section 114.

The housing sections 112,114 and the heat sink 110 cooperatively form anenclosed PFC controller chamber 108 a (see FIGS. 4 and 7). As will beexplained, the PFC controller chamber 108 a is configured to receive apower factor correction (PFC) circuit. The lower housing section 112 andmiddle housing section 114 are complementally shaped and removablyengaged with one another along margins 122,132 b that cooperatively forma continuous tongue-and-groove sealing joint 134. The sealing joint 134preferably forms a continuous, hermetic seal between the sections112,114 to restrict fluid ingress relative to the lower controllerchamber 108 a.

Turning again to FIGS. 11-14, the inductor wall 120 c is integrallyformed with the side wall 120 a and projects inboard from the side wall120 a. The inductor wall 120 c and side wall 120 a extend transverselyto the control board of the motor controller 104. The side wall 120 aextends around the control board and partly defines the PFC controllerchamber 108 a.

As will be explained, the motor controller 104 preferably has aninductor mounted to the inductor wall 120 c. The depicted inductor wall120 c presents an inboard wall surface 136 and an outboard wall surface138. The inboard wall surface 136 faces the inductor, and the inductoris secured against the inboard wall surface 136 within the PFCcontroller chamber 108 a.

The outboard wall surface 138 is located opposite the inboard wallsurface 136. The outboard wall surface 138 defines a plurality ofspaced-apart fins 140. The fins 140 preferably extend transversely to aboard plane of the control board. The inductor wall 120 c, including thefins 140, is configured to dissipate heat from the inductor via theoutboard wall surface 138.

Turning to FIGS. 17 and 32-34, the heat sink 110 is operable to removeheat generated within the control housing 102 and includes a base 142and a plurality of fins 144. Adjacent pairs of fins 144 definecorresponding fin channels 146 that extend between opposite ends 148 ofthe heat sink 110 (see FIG. 17). The fins 144 extend axially along theexterior motor surface 86. The heat sink 110 is preferably formed of analuminum alloy, but could include other materials (e.g., anothermetallic material such as carbon steel or stainless steel) within thescope of the present invention. As will be explained below, the motorfan assembly 54 is configured to direct axial air flow through the fanchannels 146 to facilitate heat transfer from the heat sink 110.

The lower housing section 112 and the heat sink 110 are removablyengaged with one another along a continuous sealing joint 150 (see FIG.34). The sealing joint 150 preferably extends along and surrounds thecentral opening 126. The sealing joint 150 also preferably forms acontinuous, hermetic seal between the lower housing section 112 and theheat sink 110 to restrict fluid or contaminant ingress relative to thePFC controller chamber 108 a.

Turning to FIGS. 3, 4, 7, and 15, the upper housing section 116 includesa continuous side wall 152 a and an upper wall 152 b. The side wall 152a extends about the upper wall 152 b to form a continuous perimetermargin 154 of the upper housing section. The upper housing section 116also includes a series of gussets 156 to reinforce the upper wall 152 b(see FIG. 4). The upper wall 152 b defines an upper pocket 158 toreceive the user interface (see FIG. 3).

The middle housing section 114 and the upper housing section 116cooperatively form a low-voltage controller chamber 108 b and ahigh-voltage controller chamber 108 c (see FIG. 4). The middle housingsection 114 and upper housing section are complementally shaped and areremovably engaged with one another along a continuous sealing joint 160.The sealing joint 160 preferably forms a continuous, hermetic sealbetween the sections 114,116 to restrict fluid ingress relative to thecontroller chambers 108 b and 108 c.

The dividing wall 130 c of the middle housing section 114 and one of thegussets 156 are removably engaged with one another along a joint 162 toseparate the low-voltage controller chamber 108 b and the high-voltagecontroller chamber 108 c from one another (see FIG. 4). The joint 162preferably restricts fluid communication between the low-voltagecontroller chamber 108 b and the high-voltage controller chamber 108 c.

The dividing wall 130 c preferably receives an elastomeric grommet 164that provides a sealed feedthrough location along the dividing wall 130c (see FIGS. 5 and 6). The grommet 164 is operable to receive a wiringharness 165 and allow the wiring harness 165 to extend between thecontroller chambers 108 b and 108 c (see FIGS. 5 and 6). The grommet 164cooperates with the dividing wall 130 c and the respective gusset 156 toprovide the sealing joint 162 between the controller chambers 108 b and108 c.

The user interface housing 118 includes a frame 166 and a user interfacecover 168 rotatably connected to one another by a hinge 170 (see FIGS. 1and 4). The frame 166 presents a frame opening 172 to operably receivethe user interface of the motor controller 104 (see FIG. 4).

The lower housing section 112, middle housing section 114, upper housingsection 116, and user interface housing 118 are all preferably formed ofa synthetic resin material, although one or more of these componentscould include an alternative material without departing from the ambitof certain aspects of the present invention.

The depicted control housing 102 is preferably configured to providesealed controller chambers 108 a,b,c and operably enclose components ofthe motor controller 104. The principles of the present invention areequally applicable where the control housing is alternatively configuredto suitably house elements of the controller. For some aspects of thepresent invention, it will be understood that at least some componentsof the control housing and/or the controller could be integrallyprovided as part of the electric motor. It will also be appreciated thatthe shape of the control housing may vary without departing from thescope of the present invention. Furthermore, certain aspects of thepresent invention contemplate different housing sectional arrangementsor no sectioning at all.

Motor Controller and Inductor

Referring again to FIGS. 3-14, the motor controller 104 preferablyincludes a power factor correction (PFC) circuit board 174, alow-voltage drive interface board 176, a high-voltage interface 178, arelay board 180, and a user interface 182 (see FIGS. 4-6).

In the customary manner, the user interface 182 enables the operator tochange one or more motor settings associated with motor (and preferablypump) operation. The user interface 182 includes an interface circuitboard 184, a user interface display 186, and user interface controls 188(see FIG. 4).

The PFC circuit board 174 is configured to facilitate adjustment ofmotor settings and provide corresponding control of motor operation. ThePFC circuit board 174 includes, among other things, a control board 190,heat-generating electrical components 192, and an inductor 194 (seeFIGS. 10 and 17).

The control board 190 is configured to support various electricalcomponents and is mounted within the PFC controller chamber 108 a. Thecontrol board 190 defines a board plane 196 and presents a perimetermargin 198 (see FIGS. 8 and 9). The perimeter margin 198 forms a notchedopening that partly defines an open space 200 to receive the inductor194 (see FIGS. 11 and 12).

In alternative embodiments, one or more elements of the control board190 could be alternatively configured and/or positioned within thecontrol housing (e.g., to provide suitable motor operation) withoutdeparting from the scope of the present invention.

Turning to FIGS. 8-12, the inductor 194 is operable for use as part ofthe PFC circuit board 174 to adjust the power factor associated withelectrical power supplied to the electric motor 52. Preferably, the PFCcircuit, including the inductor 194, is configured to increase the powerfactor, although other adjustments to the power factor are within theambit of the present invention. The depicted inductor 194 includes ametal inductor core 202 and inductor windings 204 wrapped around thecore 202 (see FIG. 8).

The illustrated inductor core 202 preferably has a toroidal core bodywith a generally circular core axis A2 (see FIG. 12). The windings 204are preferably wrapped about the core axis A2 to form a series of loops204 a (see FIG. 12).

Preferably, the inductor core 202 and inductor windings 204cooperatively present an inner margin 206 that defines an inductoropening 208 (see FIG. 12). The inductor opening 208 extends through theinductor core 202 along an inductor axis A3 (see FIG. 10).

The inductor 194 is operably coupled to the control board 190 by leads204 b of the windings 204 (see FIGS. 8 and 9). The leads 204 b arecoupled to contacts 210 associated with the control board 190 (see FIGS.8 and 9).

The toroidal shape of the depicted inductor 194 is preferable. However,in alternative embodiments, the inductor could have an alternativeinductor shape (e.g., cylindrical, rod-shaped, etc.) within the scope ofthe present invention.

The inductor 194 and the rest of the PFC circuit board 174 arepreferably located within the control housing 102 to optimize the use ofspace within the control housing 102 and enable the design of thecontrol housing 102 to have a small form factor.

The motor controller 104 includes an inductor fastener assembly 212 thatextends through the inductor opening 208 to secure the inductor 194 tothe control housing 102. The inductor fastener assembly 212 includes aninsulation pad 212 a, a silicone washer 212 b, a spacer 212 c, and athreaded fastener 212 d (see FIGS. 10 and 12).

The insulation pad 212 a and the silicone washer 212 b are receivedbetween the spacer 212 c and the inductor 194. The spacer 212 c extendsthrough the inductor opening 208 and is secured to the inductor wall 120c by the threaded fastener 212 d. A thermal pad 214 is positionedbetween the inductor 194 and the inductor wall 120 c and is operable toconduct heat from the inductor 194 to the inductor wall 120 c tofacilitate dissipation of heat from the inductor 194 (see FIGS. 10 and12). Although the inductor fastener assembly 212 and the thermal pad 214are preferred for mounting the inductor 194, one or more of thesecomponents could be alternatively configured to suitably mount theinductor.

The inductor 194 is attached to the control housing 102 and positionedwithin the PFC controller chamber 108 a adjacent the control board 190.When secured to the inductor wall 120 c, the inductor 194 is located atleast partly within the open space 200 and extends into and out of thecorresponding channel 128. The inner margin 206 of the inductor 194circumscribes the spacer 212 c. The inductor 194 is also positioned toextend radially relative to the inductor axis A3 beyond opposite sidesof the control board 190. The inductor 194 is preferably arranged withinthe PFC controller chamber 108 a so that the inductor axis A3 extendssubstantially parallel to the board plane 196.

When mounted in the PFC controller chamber 108 a, the inductor 194defines maximum first and second inductor dimensions D1,D2 measuredalong corresponding first and second directions (see FIG. 11). The firstand second directions are generally parallel to the board plane 196 andorthogonal to one another. As used herein, when referring to a feature(e.g., a dimension) as being parallel to the board plane, it is withinthe scope of the present invention for such feature, if the featureincludes or is part of a planar component, to be coplanar with the boardplane.

The inductor 194 further defines a maximum third inductor dimension D3measured along a third direction transverse to the board plane 196 (seeFIG. 12). In the depicted embodiment, the second and third inductordimensions D2 and D3 are diametrical dimensions of the inductor 194.Preferably, at least one of the first and second inductor dimensionsD1,D2 is less than the maximum third inductor dimension D3. Again,because the illustrated inductor 194 is toroidal in shape, the secondand third inductor dimensions D2 and D3 are substantially identical,with the first inductor dimension D1 being less than both. Whenreferring to a “maximum” dimension of the inductor, the maximumdimension refers to the maximum size of the inductor as measured in thecorresponding direction. That is to say, the maximum dimensionconstitutes the greatest length of the inductor in the correspondingdirection, regardless of where that maximum dimension might fall alongthe body.

In the depicted embodiment, the control board 190 and the board plane196 extend laterally. As a result, the inductor 194 is arranged in agenerally upright orientation. The inductor 194 is preferably orientedrelative to the control board 190 to optimize the use of space withinthe control housing 102. The illustrated inductor orientation alsopreferably enables the control housing 102 to have a small form factor.

Still referring to FIGS. 8-12, the inboard wall surface 136 of theinductor wall 120 c faces the inductor 194 and restricts movement of theinductor 194 within the PFC controller chamber 108 a. In the illustratedembodiment, the inboard wall surface 136 spans the inductor 194 and isat least coextensive with the inductor 194. In particular, the inboardwall surface 136 is at least coextensive with the length of the firstinductor dimension and the length of the third inductor dimension.

In alternative embodiments, the inductor wall 120 c could bealternatively configured to extend along and support the inductor (e.g.,where the inductor wall is not coextensive with the inductor).

Clamp Assembly

Turning to FIGS. 15-23, the clamp assembly 106 is configured to engageheat-generating electrical components 192 to facilitate transfer of heatfrom the components 192 to the heat sink 110. In the depictedembodiment, the clamp assembly 106 is operable to engage at least threeheat-generating electrical components 192 (which are preferably arrangedside-by-side) and clamp the electrical components 192 relative to theheat sink 110. The clamp assembly 106 preferably includes a clamp bar216 and threaded fasteners 218 to secure the clamp bar 216 to the heatsink 110.

The electrical components 192 clamped in place by the clamp assembly 106are preferably MOSFETs, but other heat-generating electrical componentscould be engaged by the clamp assembly 106. As will be discussed, theelectrical components 192 each present a thickness dimension.

The disclosed motor controller 104 preferably has three (3) electricalcomponents 192 arranged along and operably coupled to the control board190 (see FIG. 15). However, the principles of the present invention areapplicable where an alternative number of electrical components 192(whether the components 192 include MOSFETs and/or other heat-generatingelectrical components) are positioned along the control board 190.

The electrical components 192 are preferably arranged in series alongthe length of the clamp bar 216. Furthermore, the electrical components192 are generally axially aligned with one another along a longitudinalclamp axis A4 (see FIG. 23). However, the electrical components 192could be alternatively positioned consistent with the scope of thepresent invention. In alternative embodiments, the electrical componentscould be arranged in series along the clamp bar length, but with one ormore components being laterally offset from the longitudinal clamp axis.

The clamp bar 216 preferably includes a clamp margin 220 and a backingflange 222. The backing flange 222 essentially serves as a support forthe clamp margin 220 (see FIGS. 22 and 23). The depicted clamp margin220 extends continuously along the length of the clamp bar 216. Theclamp margin 220 preferably defines three (3) spaced apart projections224 and presents a clamping surface 226 (see FIGS. 22 and 23). Thebacking flange 222 presents a flange surface 228 opposite the clampingsurface 226 (see FIGS. 19 and 22). The clamping surface 226 and flangesurface 228 cooperatively define a maximum clamp height dimension H1(see FIG. 19). The clamp bar 216 also presents a slot 230 and a pair offastener openings 232 (see FIGS. 22 and 23).

Preferably, the slot 230 extends transversely to the clamp axis A4 andis positioned between two of the projections 224. The depicted slot 230also defines respective clamp bar sections 216 a on opposite sides ofthe slot 230. In particular, the slot 230 intersects the flange surface228 and extends transversely from the flange surface 228 toward theclamping surface 226. Preferably, the slot 230 extends through thebacking flange 222 to present flange sections 222 a separated by theslot 230. In the depicted embodiment, the flange sections 222 a areassociated with respective clamp bar sections 216 a.

The depicted slot 230 is described as extending transversely to theclamp axis A4. While the illustrated slot 230 and clamp axis A4 aregenerally perpendicular to one another, it will be understood that theslot and clamp axis could extend transversely to one another withoutbeing perpendicular. That is, the slot could simply extend across theclamp axis, and it will be appreciated that the angle formedtherebetween could vary within the ambit of the present invention.

Although the slot 230 extends through the backing flange 222, inalternative embodiments, the slot 230 could extend through at least oneof the clamp margin 220 and the flange 222 to provide desirable clampfunctionality. For instance, the slot 230 could be variously configuredso that the clamp bar 216 is flexible along its length and allows theclamp bar sections 216 a to shift relative to one another.

The configuration of slot 230 and the clamp margin 220 permits the clampbar sections 216 a to shift relative to one another about a transverseaxis to facilitate clamping engagement of the projections 224 with theelectrical components 192. In particular, the reduced cross-sectionaldimension of the clamp bar 216 at the location of the slot 230facilitates flexing. More particularly, the clamp margin 220 isflexible, thereby facilitating shifting of the clamp bar sections 216 agenerally about the portion of the clamp margin 220 interconnecting theclamp bar sections (i.e., the portion of the clamp margin 220 underlyingthe slot 230). Yet further, the slot 230 serves to space the flangesections 222 apart to allow shifting of the clamp bar sections 216 a.Therefore, the slot 230 and clamp margin 220 cooperatively permitshifting of the clamp bar sections 216 a toward one another (see FIG.20) or away from one another (see FIG. 21). As will be discussed, theclamp bar sections 216 a are preferably relatively shiftable so that theclamp bar 216 engages each of the electrical components 192.

The clamp bar 216 is preferably formed of a synthetic resin material. Byincluding a synthetic resin material, the clamp bar 216 preferablyserves as an insulator. The synthetic resin material also preferablypermits flexing of the clamp bar, as discussed above. For certainaspects of the present invention, the clamp bar could include,alternatively or additionally, a metallic material (such as carbon steelor aluminum). It will be appreciated that metallic features of the clampbar could be cast, machined, and/or formed by other manufacturingmethods.

In alternative embodiments where the clamp bar includes a metallicmaterial, the alternative clamp bar also preferably includes at leastsome insulation material (e.g., a synthetic resin) used in combinationwith a metallic portion of the clamp bar. The insulation material can bevariously provided with the metallic portion within the scope of thepresent invention. For instance, an insulation portion comprised ofsynthetic resin could be molded onto the metallic portion. Similarly,one or more insulation layers could be attached (e.g., adhered) relativeto the metallic portion.

The projections 224 are configured to be located in engagement with therespective electrical components 192. The projections 224 are depictedas being in direct contact with the electrical components 192. However,when referring to the projections as being in engagement with theelectrical components, it will be understood that one or more materiallayers may be interposed between the projections and electricalcomponents. For instance, such interposed layers may include a film(e.g., a film including a synthetic resin material, such as Mylar®),fabric, paste, grease, liquid, and/or other material. One or moreinterposed layers may be considered as integrally part of the electricalcomponents. In any event, any interposed layers are preferablyconfigured to permit the clamp bar to apply a clamping force to theelectrical components.

In the depicted embodiment, the projections 224 are spaced in seriesalong the length of the clamp bar 216 to provide opposite endmostprojections 224 and an intermediate projection 224. The depictedprojections 224 are spaced along and define the clamp axis A4. The clampmargin 220 extends continuously between the endmost projections to jointhe clamp bar sections 216 a. In the depicted embodiment, the slot 230is longitudinally aligned with the intermediate projection 224.

The fastener openings 232 each extend transversely through the clampmargin 220 and the backing flange 222. Each fastener opening 232 ispreferably positioned between a respective pair of adjacent projections224. In this manner, the clamp assembly 106 is preferably configured sothat each fastener 218 is located between the respective pair ofadjacent projections 224 (and also between corresponding electricalcomponents 192). The fastener openings 232 are preferably arranged inseries along the length of the clamp bar 216 and generally axiallyaligned with one another along the longitudinal clamp axis A4.

Although the clamp bar 216 includes a pair of fastener openings 232,alternative embodiments of the clamp bar could have more than twofastener openings or a single fastener opening. For instance, the clampbar could have four projections and three fastener openings, with eachfastener opening located between a respective adjacent pair ofprojections. For certain aspects of the present invention, the clamp barcould also present a common opening to receive two or more fasteners. Insuch an alternative embodiment, the clamp bar could present an elongatedslotted opening that extends transversely through the clamp margin 220and the backing flange 222 while extending along the clamp axis.

It is also within the ambit of the present invention where the fasteneropenings are alternatively located along the clamp bar. For instance,the fastener openings could be arranged in series, but with one or morefastener openings being laterally offset from the longitudinal axis. Forsome aspects of the present invention, the clamp bar could be devoid offastener openings (e.g., where an alternative fastener is used to securethe clamp bar).

The fasteners 218 are configured to engage the flange sections 222 a tohold the clamp bar 216 against the electrical components 192. Thefasteners 218 comprise conventional machine screws that are removablyreceived by the clamp bar 216, but could include other types offastening devices or elements within the ambit of the present invention.For example, in alternative embodiments, a fastener could comprise oneor more of a bolt, nut, washer, pin, rivet, adhesive, or weld. It isalso within the scope of the present invention where at least part ofthe fastener is integrally formed with the clamp bar.

Although the clamp bar 216 includes a pair of fasteners 218, alternativeembodiments of the clamp bar could have more than two fasteners or asingle fastener. It is also within the ambit of the present inventionwhere the fasteners are alternatively located along the clamp bar. Forinstance, the fasteners could be arranged in series, but with one ormore fasteners being laterally offset from the longitudinal axis. Forsome aspects of the present invention, the clamp bar assembly could bedevoid of fasteners.

In use, the clamp bar 216 is configured to engage heat-generatingelectrical components 192 and urge the electrical components against theheat sink 110. The electrical components are depicted as being in directcontact with the heat sink 110. However, when referring to theelectrical components as being in engagement with the heat sink, it willbe understood that one or more material layers may be interposed betweenthe electrical components and the heat sink. For instance, suchinterposed layers may include a film (e.g., a film including a syntheticresin material, such as Mylar®), fabric, paste, grease, liquid, and/orother material. Again, one or more interposed layers may be consideredas integrally part of the electrical components. An interposed layerbetween the electrical components and the heat sink is preferably tofacilitate heat conduction from the electrical components to the heatsink. Any interposed layers are preferably configured to permit theelectrical components to be clamped against the heat sink.

The clamp assembly 106 is preferably configured to engage variousarrangements of electrical components. In one embodiment, the clamp bar216 is illustrated as engaging electrical components 192 that each havesubstantially the same thickness dimension T1 (see FIG. 19). However,the clamp bar 216 is preferably operable to engage electrical components192 with different thickness dimensions T1,T2,T3 (see FIGS. 20 and 21).

Again, the clamp bar sections 216 a are preferably relatively shiftableso that the clamp bar 216 can engage each electrical component 192. Morespecifically, the clamp bar 216 is configured to flex to facilitateclamping engagement of the projections 224 with the electricalcomponents 192. This configuration enables the clamp bar 216 to engageelectrical components having different thickness dimensions T1,T2,T3.

In one such example, the clamp bar sections 216 a can flex away from theheat sink 110 to engage an intermediate electrical component 192 with athickness dimension T1 shorter than a thickness dimension T2 of adjacentelectrical components 192 (see FIG. 20).

In another example, the clamp bar sections 216 a can flex toward theheat sink 110 to engage endmost electrical components 192 with athickness dimension T3 shorter than a thickness dimension T1 of anintermediate electrical component 192 (see FIG. 21). For certain aspectsof the present invention, the clamp bar could be secured so that oneclamp bar section flexes toward the heat sink and another clamp barsection flexes away from the heat sink.

Again, in the depicted embodiment, the projections 224 are arranged inseries along the length of the clamp bar 216. Furthermore, theprojections 224 are generally axially aligned with one another along thelongitudinal clamp axis A4 of the clamp bar 216.

However, the projections 224 could be alternatively positioned accordingto certain aspects of the present invention. In alternative embodiments,the projections could be arranged in series along the clamp bar length,but with one or more projections being laterally offset from thelongitudinal axis. In one alternative example, the clamp bar could havethree (3) projections arranged in a triangular configuration such thateach projection is located at a respective point of the triangle. Insuch an alternative embodiment, it will be understood that any pair ofprojections would cooperatively define a respective clamp axis.

Turning to FIGS. 24-27, an alternative clamp assembly 234 is depicted aspart of the motor controller. The alternative clamp assembly 234includes an alternative clamp bar 236 and fasteners 218.

The clamp bar 236 preferably includes an alternative clamp margin 238, abacking flange 240, and spacers 242 projecting from the clamp margin238. The clamp margin 238 defines three spaced apart projections 244.

The depicted spacers 242 each preferably include a sleeve having agenerally tubular shape. The spacers 242 are located between respectiveadjacent pairs of projections 244. However, one or more spacers could bealternatively configured and/or positioned without departing from thescope of the present invention.

The flange 240 includes flange sections 240 a defined on opposite sidesof a slot 245. The clamp bar 236 also presents fastener openings 246extending transversely through the flange sections 240 a, the clampmargin 238, and through respective spacers 242.

The inside diameter of the fastener openings 246, particularly along thespacers 242, is preferably oversized relative to the outside diameter ofthe threaded body of the fasteners 218. The oversized fastener openings246 preferably accommodates a slight angular cant of the spacers 242(and, generally, the clamp bar sections) associated with flexing of theclamp bar.

The spacers 242 serve a number of purposes. For example, in certainarrangements, the spacers 242 may restrict the clamp bar 236 fromapplying too much clamping force to the electrical components 192 (i.e.,by overly tightening the fasteners 218). When in clamping engagementwith the electrical components 192, the spacers 242 and the heat sink110 preferably define a slight gap G therebetween (see FIG. 25),although contact between the bottom of the spacer 242 and the heat sink110 will restrict or limit the clamping force. Furthermore, the spacersgenerally encapsulate the fasteners 218 (which are preferably metal andpossibly electrically conductive) and thereby reduce the risk of arcingto the fasteners.

In FIGS. 28-31, another alternative clamp assembly 248 is depicted. Thealternative clamp assembly 248 includes an alternative clamp bar 250 andfasteners 218.

The clamp bar 250 preferably includes a clamp margin 252 and a backingflange 254 to support the clamp margin 252. The clamp margin 252 definesthree (3) spaced apart projections 256.

The backing flange 254 includes flange sections 254 a defined onopposite sides of a slot 257. The backing flange 254 presents a flangesurface 258 opposite a clamping surface 260. The clamping surface 260and flange surface 258 cooperatively define a maximum clamp heightdimension H2. The clamp bar 250 is similar to clamp bar 216, but theclamp bar 250 preferably has a maximum clamp height dimension H2 greaterthan the height dimension H1 of clamp bar 216. More preferably, theratio of the maximum clamp height dimension H2 of clamp bar 250 to theheight dimension H1 of clamp bar 216 is about 2/1, although this ratiocould also range from about 1.5/1 to about 3/1 within the scope of thepresent invention.

Motor Fan Assembly

Turning to FIGS. 2 and 32-42, the motor fan assembly 54 serves to directairflow toward the heat sink 110, thereby facilitating heat dissipationfrom the heat sink 110. The motor fan assembly 54 broadly includes theradial fan 98 and the fan guard 100.

The radial fan 98 is configured to drive airflow to the heat sink 110.The radial fan 98 is preferably mounted on the rotatable shaft 70exteriorly of the motor housing 60 and is rotatable with the shaft 70 ina rotation direction R (see FIGS. 32 and 40) to direct airflow radiallyoutwardly.

In the illustrated embodiment, the radial fan 98 is unitary and includesa hub 266 and a wheel 268. The radial fan 98 presents a rotational axisA5 about which the radial fan 98 rotates (see FIGS. 40 and 42). It willbe appreciated that the rotational axis A5 and the shaft axis A1 aresubstantially coaxial in the illustrated embodiment. In the usualmanner, the hub 266 presents a shaft hole 270 receiving the exposedportion 74 b of the shaft 70 when the radial fan 98 is mounted on theshaft 70.

The radial fan 98 is fixed relative to the shaft 70 outside the housing60 and is rotatable with the shaft 70 to direct air flow radiallyoutwardly. Most preferably, the radial fan 98 is fixedly attacheddirectly to the shaft 70. Again, it is within the scope of the presentinvention where the radial fan 98 is mounted on an output shaft otherthan the shaft 70 (e.g., a transmission output shaft). In such analternative embodiment, it will be understood that the rotational axisand the rotor shaft axis could be coaxial or axially offset from oneanother (e.g., depending on the configuration of the transmission).

In the preferred embodiment, the shaft hole 270 is complementally sizedand shaped so that the shaft 70 is snugly received in the shaft hole270. In the depicted embodiment, the radial fan 98 is preferablyfrictionally engaged with the shaft 70 so as to be fixedly attachedthereto (see FIG. 7).

However, it is within the scope of certain aspects of the presentinvention for the hub to be alternatively configured for drivingattachment to the output shaft. For instance, although the illustratedhub provides a non-circular bore, the hub could have a profile shapethat is splined or has a circular shape for mating with a correspondingshape of the output shaft.

In various alternative embodiments, the hub could be alternatively fixedto the output shaft, whether or not the output shaft extends entirelythrough the hub. For instance, the hub could be secured to the outputshaft with one or more fasteners (e.g., a set screw, cotter pin, etc.).In addition, the hub may be press fit to the shaft. Also in alternativeembodiments, the hub could be configured so that the output shaftextends only partly through the hub or does not project from both endsof the hub.

The illustrated wheel 268 drives airflow radially outwardly. Preferably,the wheel 268 includes a wheel plate 272 and a plurality of radiallyextending fan blades 274. Preferably, the wheel plate 272 and fan blades274 cooperatively form a series of passages 276 (see FIG. 40) extendingradially outward relative to the hub 266.

The wheel plate 272 is supported by the hub 266 and located axiallyoutboard of the housing 60 when the motor 52 is secured for operation.The wheel plate 272 of the illustrated embodiment is preferablycontinuous and extends to an outer plate margin 278 (see FIG. 40). Theouter plate margin 278 extends circumferentially so that the wheel plate272 is generally circular in shape and presents opposed notches 280.

For some aspects of the present invention, the wheel plate 272 could bealternatively constructed (e.g., where the wheel plate 272 is notcontinuous). The depicted wheel plate 272 is fixed to the hub 266 and ispreferably positioned so that the center of the outer plate margin 278corresponds to the rotational axis A5. Those of skill in the art willalso appreciate that the wheel plate could be alternatively shapedwithout departing from the principles of the present invention.

The fan blades 274 partly define the passages 276 and facilitate airflowin a radially outward direction within the passages 276. Each adjacentpair of fan blades 274 presents a fan discharge opening 282 throughwhich airflow is discharged from the corresponding passage 276 (see FIG.40).

Each fan blade 274 presents an exterior blade surface 284 having acurvilinear airfoil profile (see FIG. 38). The airfoil profile defines aleading edge 286, a trailing edge 288, and a longitudinal edge 290 (seeFIG. 38). The leading edge 286 is spaced radially inside the trailingedge 288. The airfoil profile also defines a curved camber line 292extending between the leading edge 286 and the trailing edge 288 (seeFIG. 40).

The exterior blade surface 284 of each fan blade 274 includes pressureand suction surfaces 284 a,b on opposite sides of the camber line 292and extending radially between the leading edge 286 and the trailingedge 288 (see FIG. 40). Preferably, the pressure surface 284 a facesinto the rotational direction R, and a portion of the pressure surface284 a is concave. The suction surface 284 b preferably faces oppositelyfrom the rotational direction R, and at least part of the suctionsurface 284 b is convex.

However, the pressure surface and/or suction surface of the fan bladecould be alternatively configured without departing from the scope ofcertain aspects of the present invention. For instance, although amajority of the pressure surface 284 a is concave, the pressure surfacecould have one or more alternative portions that include convex, flat,and/or concave features. Similarly, although the suction surface 284 bis generally convex, the suction surface could have one or morealternative portions that include convex, flat, and/or concave features.

The airfoil profile of each fan blade 274 also preferably has a chordline 294 comprising a straight line that extends through the leadingedge 286 and the trailing edge 288 (see FIG. 40). Each fan blade 274 isassociated with a radial line extending through the rotational axis A5and the leading edge 286. The chord line 294 and the radial line of thedepicted fan blades 274 are off-axis to define an angle of attack θtherebetween (see FIG. 40). Preferably, the chord line 294 extends fromthe radial line along a direction opposite the rotational direction R.

Again, in accordance with certain aspects of the present invention, thefan blades could also have an alternative blade shape. For instance, thefan blades could have an alternative curved airfoil shape (e.g., toinduce a greater airflow). For some aspects of the present invention,one or more fan blades could include flat blade sections.

The radial fan 98 preferably comprises a synthetic resin material, suchas an elastomeric material. It is equally within the ambit of thepresent invention where the radial fan includes, alternatively oradditionally, one or more other materials. For instance, the radial fancould include one or more metallic materials (e.g., carbon steel,stainless steel, and/or aluminum).

In the illustrated embodiment, the radial fan 98 preferably comprises aone-piece construction. However, for some aspects of the presentinvention, the radial fan could include multiple components that areattached to one another (e.g., where the components are welded, adhered,fastened, and/or otherwise secured to one another).

Turning to FIGS. 34-37, the illustrated fan guard 100 preferablyprotects the radial fan 98, particularly during fan operation. The fanguard 100 is also preferably operable to direct airflow from the radialfan 98 toward the heat sink 110. The fan guard 100 preferably includes afan cover 296 and an air scoop 298 that are integrally formed with oneanother.

The fan guard 100 is mounted relative to the motor housing 60 andextends over the radial fan 98. The fan guard 100 cooperates with themotor housing 60 to define a fan chamber 300 and a fan outlet opening302 (see FIG. 34). The fan chamber 300 extends between a fan inletopening 304 and the fan outlet opening 302.

The fan cover 296 includes a central grate 306 and a peripheral skirt308 that extends axially from the central grate 306. The skirt 308extends circumferentially about the central grate 306 and presentsmultiple fastener openings 310.

In the depicted embodiment, the central grate 306 presents the fan inletopening 304. The radial fan 98 is operable to draw air axially into fanchamber 300 via the fan inlet opening 304.

The skirt 308 is preferably sized to be received on one end of the motorhousing 60. Radially-extending threaded fasteners 312 are inserted inthe openings 310 and threaded into bosses 314 associated with theendshield 82 (see FIG. 35). The fan guard 100 is arranged so that theradial fan 98 is axially outboard of the fasteners 312.

Although the fan guard 100 preferably includes the fan cover 296, thefan cover could be alternatively configured without departing from thescope of the present invention. For certain aspects of the invention,the motor fan assembly could be devoid of a fan cover. For instance, themotor fan assembly could use an air scoop without using a fan cover.

In the illustrated embodiment, the air scoop 298 is operable to receiveradial airflow from the radial fan 98 and turn the airflow axially. Theair scoop 298 preferably includes a scoop body 316 and spaced apartaxially extending airflow vanes 318. The airflow vanes 318 at leastpartly define scoop channels 319 that extend axially along the airflowvanes 318 (see FIG. 37). The airflow vanes 318 guide the airflow as theair scoop 298 turns the airflow axially.

The air scoop 298 partly defines the fan outlet opening 302 of the fanchamber 300, with axial airflow being discharged by the fan outletopening 302. The air scoop 298 presents an air scoop inlet 320 and anair scoop outlet 322 (see FIG. 34). The scoop body 316 preferablypresents a curved inside face 324 located between the air scoop inlet320 and the air scoop outlet 322. The curved inside face 324 generallydefines the airflow turn provided by the air scoop 298. In the depictedembodiment, the airflow vanes 318 project from the inside face 324. Forcertain aspects of the present invention, the inside face of the airscoop (or other parts of the air scoop) could have an alternative shapeand/or configuration for turning the airflow axially.

The airflow vanes 318 extend between the air scoop inlet 320 and the airscoop outlet 322. The fan blades 274 extend along an axial bladedimension D4 (see FIG. 34). The depicted air flow vanes 318 are alignedaxially with at least part of the axial blade dimension D4. Within theambit of the present invention, the air flow vanes could be configuredto extend along only part of the axial extent of the fan blades. Forcertain aspects of the present invention, the air flow vanes could beentirely axially offset from the fan blades.

The air scoop outlet 322 is associated with the fan outlet opening 302in the depicted embodiment. The air scoop 298 extends radially outwardlyrelative to the radial fan 98 and axially along the rotational axis A5to receive radial airflow and turn the airflow axially to flow throughthe air scoop outlet 322 and along the exterior motor surface 86.

The fan guard 100 is installed so that the fan outlet opening 302 isgenerally aligned with and communicates with one end 148 of the heatsink 110. Preferably, at least some of the airflow vanes 318 are ingeneral alignment with corresponding fins 144 of the heat sink 110. Thescoop channels 319 are also preferably in at least partial alignmentwith respective fin channels 146 of the heat sink 110. Thus, as theradial fan 98 produces airflow, the airflow is turned axially by the airscoop 298 and discharged axially to flow through the fin channels 146 ofthe heat sink 110. In this manner, the motor fan assembly 54 facilitatesheat transfer out of the heat sink 110 during motor operation.

Although the above description presents features of preferredembodiments of the present invention, other preferred embodiments mayalso be created in keeping with the principles of the invention. Suchother preferred embodiments may, for instance, be provided with featuresdrawn from one or more of the embodiments described above. Yet further,such other preferred embodiments may include features from multipleembodiments described above, particularly where such features arecompatible for use together despite having been presented independentlyas part of separate embodiments in the above description.

The preferred forms of the invention described above are to be used asillustration only, and should not be utilized in a limiting sense ininterpreting the scope of the present invention. Obvious modificationsto the exemplary embodiments, as hereinabove set forth, could be readilymade by those skilled in the art without departing from the spirit ofthe present invention.

The inventors hereby state their intent to rely on the Doctrine ofEquivalents to determine and assess the reasonably fair scope of thepresent invention as pertains to any apparatus not materially departingfrom but outside the literal scope of the invention as set forth in thefollowing claims.

The invention claimed is:
 1. An electric motor assembly comprising: astator; a rotor rotatable relative to the stator; a motor housing inwhich the stator and rotor are at least partly housed, with the motorhousing presenting an exterior motor surface; a rotatable shaftassociated with the rotor for rotational movement therewith, with therotatable shaft extending along a rotational axis; a radial fan mountedon the rotatable shaft exteriorly of the motor housing and rotatablewith the shaft to direct airflow in a radially outward direction; and anair scoop extending radially outwardly relative to the radial fan andaxially to receive radial airflow from the radial fan and turn theairflow axially to flow along the exterior motor surface, said air scoopincluding circumferentially spaced apart axially extending airflow vanesto guide the airflow as the airflow is turned axially to flow along anaxial flow direction, said radial fan including a plurality of fanblades that extend radially outwardly relative to the rotational axis,with the fan blades extending along an axial blade dimension, each ofsaid airflow vanes including a first portion aligned axially with atleast part of the axial blade dimension and a second portion extendingcontinuously from the first portion and axially beyond the fan blades inthe axial flow direction.
 2. The electric motor assembly as claimed inclaim 1, further comprising: a fan guard mounted relative to the motorhousing and covering at least part of the radial fan, said fan guardincluding the air scoop.
 3. The electric motor assembly as claimed inclaim 2, said motor housing cooperating with the fan guard to define afan chamber extending between a fan inlet opening and a fan outletopening, said air scoop at least partly defining the fan outlet openingof the fan chamber, with axial airflow being discharged by the fanoutlet opening.
 4. The electric motor assembly as claimed in claim 3,said fan guard presenting the fan inlet opening, with the radial fandrawing air axially into fan chamber via the fan inlet opening.
 5. Theelectric motor assembly as claimed in claim 4, each adjacent pair ofsaid fan blades presenting a fan discharge opening through which airflowis discharged from the radial fan.
 6. The electric motor assembly asclaimed in claim 2, said air scoop presenting an air scoop inlet and anair scoop outlet, said air flow vanes being located between the airscoop inlet and the air scoop outlet.
 7. The electric motor assembly asclaimed in claim 2, said motor housing including a shell and anendshield, with the fan guard overlying the endshield, said motorhousing cooperating with the fan guard to define a fan chamber extendingbetween a fan inlet opening and a fan outlet opening.
 8. The electricmotor assembly as claimed in claim 7, said fan guard including a centralgrate that presents the fan inlet opening, said fan guard including aperipheral skirt that extends axially from the central grate, saidperipheral skirt being attached to the motor housing.
 9. The electricmotor assembly as claimed in claim 8, said peripheral skirt beingsecured to the motor housing with radially-extending fasteners, with theradial fan being axially outboard of the fasteners.
 10. The electricmotor assembly as claimed in claim 2, further comprising: a motorcontrol assembly, said motor control assembly including a heat sink. 11.The electric motor assembly as claimed in claim 10, said heat sinkincluding fins extending axially along the exterior motor surface, withadjacent pairs of fins defining fin channels, said air scoop beingpositioned adjacent one end of the heat sink and configured to dischargethe airflow from the fan chamber through the fin channels.
 12. Theelectric motor assembly as claimed in claim 11, said motor housingcooperating with the fan guard to define a fan chamber extending betweena fan inlet opening and a fan outlet opening, said second portion ofeach of the airflow vanes extending to the fan outlet opening andlocated adjacent the one end of the heat sink.
 13. The electric motorassembly as claimed in claim 1, each of said fan blades presenting anexterior blade surface having a curvilinear airfoil profile, saidairfoil profile defining a leading edge, a trailing edge, and a curvedcamber line extending between the edges, with the leading edge spacedradially inside the trailing edge.
 14. The electric motor assembly asclaimed in claim 13, said radial fan being rotatable with the shaft in arotation direction, said exterior blade surface of each fan bladeincluding pressure and suction surfaces on opposite sides of the camberline and extending radially between the leading edge and the trailingedge, said pressure surface facing the rotation direction and at leastpart of the pressure surface being concave.
 15. The electric motorassembly as claimed in claim 14, said airfoil profile of each fan bladehaving a chord line that extends through the leading edge, each of saidfan blades being associated with a radial line extending through therotational axis and the leading edge, said chord line and said radialline being angularly offset relative to one another to define an angleof attack therebetween, with the chord line extending from the radialline in a direction opposite the rotation direction.
 16. The electricmotor assembly as claimed in claim 13, said airfoil profile of each fanblade having a chord line that extends through the leading edge, each ofsaid fan blades being associated with a radial line extending throughthe rotational axis and the leading edge, said chord line and saidradial line being angularly offset relative to one another to define anangle of attack therebetween.
 17. The electric motor assembly as claimedin claim 1, adjacent pairs of said fan blades presenting a fan dischargeopening through which airflow is discharged from the radial fan.
 18. Theelectric motor assembly as claimed in claim 17, said air scooppresenting an air scoop inlet and an air scoop outlet, said air flowvanes being located between the air scoop inlet and the air scoopoutlet, said air flow vanes axially spanning the fan discharge openingsalong the air scoop inlet to receive airflow discharged from the radialfan.
 19. The electric motor assembly as claimed in claim 1, said rotorincluding a rotor shaft, said rotor shaft being the rotatable shaft.